BACKGROUND OF THE INVENTION
[0001] The subject matter disclosed herein relates generally to charging stations and methods
and, more particularly, to charging stations having housings and doors pivotally and
removably coupled thereto.
[0002] Electrically powered vehicles, including electric vehicles and plug-in hybrid electric
vehicles, include electric motors powered by energy storage devices, such as batteries.
Because an energy storage device is depleted of energy as the vehicle is operated,
the operator of the vehicle must recharge the energy storage device prior to using
the vehicle again.
[0003] At least some known vehicle charging stations are provided for use in various environments.
Such charging stations are designed to charge electrically powered vehicles, while
providing security and protection for components utilized in charging the vehicle.
Charging stations include a variety of constructions to hold up to the environments
in which the charging stations are installed. For example, various known charging
stations include cabinets with one or more doors hingedly attached thereto. Such doors
are generally attached by one or more external piano hinges, which restrict movement
of the door and access to components within the cabinet. Other known charging stations
do not include cabinets or housings, but instead, are constructed by assembly of sliding
panels and/ modules pluggably coupled to one another. Maintenance and/or service of
such charging stations often involve substantial disassembly of the panels and/or
the modules to gain access to components included therein.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one aspect, a charging station for use in charging an electrically powered vehicle
is provided. The charging station includes a housing defining an interior and an opening
configured to permit access to the interior, a door configured to substantially cover
the opening, and a hinge assembly configured to removably couple the door to the housing
and to provide a pivotal movement of the door relative to the housing between at least
a closed position, a first open position, and a second open position. The hinge assembly
includes a base member coupled to one of the housing and the door and a bracket coupled
to the other of the housing and the door. The base member defines an aperture. The
bracket includes a projecting member configured to be operably disposed within the
aperture. The projecting member and the base member are configured to permit removal
of the door from the housing when the door is in the first open position. The projecting
member and the base member are configured to prevent removal of the door from the
housing when the door is in the second open position
[0005] In another aspect, a charging station for use in charging an electrically powered
vehicle is provided. The charging station includes a housing defining an interior
and an opening configured to permit access to the interior, a door configured to substantially
cover the opening, and a hinge assembly configured to removably couple to the door
and the housing. The hinge assembly is configured to provide a pivotal movement of
the door relative to the housing between at least a closed position and an open position.
The hinge assembly is configured to permit removal of the door from the housing when
the door is between the closed position and the open position. The hinge assembly
is configured to prevent removal of the door from the housing when the door is in
the open position.
[0006] In yet another aspect, a method for use in operating charging station for an electrically
powered vehicle is provided. The method includes providing a door positioned in a
closed position substantially covering an opening of a housing of a charging station
for an electrically powered vehicle. A projecting member of a bracket coupled to the
door and positioned within an aperture defined by a receptacle of the charging station.
The method further includes rotating the door relative to the housing from the closed
position to a first open position, and extracting a projecting member coupled to one
of the door and the housing from an aperture of a base member to remove the door from
the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007]
Fig. 1 is a perspective view of an example charging station.
Fig. 2 is a perspective view of the charging station of Fig. 1, with a door in a first
open position.
Fig. 3 is a perspective view of the charging station of Fig. 1, with a door in a second
open position.
Fig. 4 is a sectional view of the charging station of Fig. 1, with the door in the
closed position.
Fig. 5 is a sectional view of the charging station of Fig. 1, with the door in a first
open position.
Fig. 6 is a sectional view of the charging station of Fig. 1, with the door in a second
open position.
Fig. 7 is a perspective view of an example bracket that may be included in the charging
station of Fig. 1.
Fig. 8 is a side view of the bracket of Fig. 6.
Fig. 9 is a perspective view of an example base member that may be included in the
charging station of Fig. 1.
Fig. 10 is a block diagram of an example method for use in assembling a charging station
for charging an electrically powered vehicle.
Fig. 11 is a block diagram of an example method for use in operating a charging station
for charging an electrically powered vehicle.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0008] The embodiments described herein relate generally to charging stations for charging
electrically powered vehicles. More specifically, the embodiments described herein
relate to charging stations having housings and doors pivotally and removably coupled
thereto.
[0009] Fig. 1 illustrates an example charging station 10 for use in charging an electrically
powered vehicle (not shown). In the example embodiment, charging station 10 includes
a housing 12. As shown in Figs. 2-3, housing 12 has an interior 14. Multiple vehicle
charging components 16 are positioned within interior of housing 12. Vehicle charging
components 16 may include, without limitation, power conduits, transmission lines,
power converters, power conditioners, circuit breakers, switching devices, or other
components used to provide energy transfer from charging station 10 to the electrically
powered vehicle. Housing 12 is configured to at least partially enclose vehicle charging
components 16 to protect such components from various environmental conditions, such
as, for example, weather, debris, insects, and rodents, and/or to inhibit unauthorized
access to vehicle charging components 16.
[0010] Housing 12 includes an opening 18 extending through a side wall 54 of housing 12,
which is usable by a technician to access interior 14 to provide service to one or
more of vehicle charging components 16. Opening 18 may be configured (e.g., by shape,
size, position) to provide substantial access to vehicle charging components 16 and/or
provide an aesthetic consistency with housing 12. In Fig. 1, for example, opening
18 has a substantially trapezoidal shape. In other examples, opening 18 may have a
rectangular shape or non-rectangular shape. In the example embodiment, charging station
10 further includes a door 20 configured to cover opening 18 when disposed in a closed
position, as shown in Fig. 1. Door 20 generally includes a shape and/or size substantially
consistent with, or complimentary to, opening 18. In the example shown in Fig. 1,
door 20 also defines a substantially trapezoidal shape. In other embodiments, various
other shapes and/or sizes of door 20 may be used to cover or partially cover opening
18.
[0011] Door 20 is pivotally movable from the closed position to multiple open positions
to permit access to interior 14 through opening 18, such as, for example, in Figs.
2-3. Pivotal movement between door 20 and housing 12 is provided by hinge assembly
22, which is located within interior 14 when door 20 is in the closed position. Detailed
views of hinge assembly 22 in the closed position, a first open position, and a second
open position are shown in Figs. 3-5, respectively. As shown, hinge assembly 22 includes
a bracket 24 and a base member 26. In one embodiment, bracket 24 and base member 26
are coupled to door 20 and housing 12, respectively, as shown in Figs. 3. Alternatively,
in other embodiments, bracket 24 is coupled to housing 12, while base member 26 is
coupled to door 20.
[0012] Bracket 24 includes a projecting member 28 and a mounting member 30 coupled to projecting
member 28, as shown in Fig. 6. In the example embodiment, projecting member 28 includes
two shoulders 32 and 34 and a tab 36 extending from shoulders 32 and 34. In the example
embodiment, mounting member 30 is coupled to one of door 20 and housing 12. Tab 36
is spaced from mounting member 30 and includes a first portion 56 and a second portion
58 extending at an angle from first portion 56. In one embodiment, as shown in Fig.
8, projecting member 28 and mounting member 30 are generally parallel to each other
and are offset from each other (as indicated by lines 40 and 42). Bracket 24 further
includes a first section 60 extending from projecting member 28 to mounting member
30, and which is angled with respect to both projecting member 28 and mounting member
30. It should be appreciated that various different shapes, sizes, and/or relative
positions of projecting member 28 and mounting member 30 may be used in other bracket
embodiments.
[0013] Tab 36 is configured to retain projecting member 28 within an aperture 38 (e.g.,
a hole, a notch, a slot etc.) within base member 26 at least when door 20 is disposed
in a second open position. As shown in Fig. 8, second portion 58 is disposed at an
angle 41 relative to first portion 56 of tab 36, as indicated by lines 42 and 44.
In the example embodiment, angle 41 is an obtuse angle, and more specifically, about
165 degrees. In various examples, angle 41 may include any angle between about 110
degrees and about 170 degrees. In other examples, angle 41 is an angle between about
150 degrees and about 170 degrees. It should be appreciated that other angles (e.g.,
obtuse, right, acute, or others) may also be defined between first portion 56 of tab
36 and second portion 58 of tab 36 in other embodiments.
[0014] In the example embodiment, aperture 38 is configured to receive projecting member
28. More specifically, aperture 38 is sized and/or shaped to receive at least a portion
of projecting member 28, as shown in Figs. 4-6. Further, base member 26 includes a
mounting member 39 configured to be coupled to housing 12. It should be appreciated
that base member 26 and/or aperture 38 may be configured otherwise in one or more
other embodiments, potentially depending on the configuration of bracket 24 and/or
a mounting location of base member 26.
[0015] Moreover, in the example embodiment, bracket 24 and base member 26 are constructed
from stainless steel to inhibit corrosion of bracket 24, for example, due to paint
peeling off during closing, opening and removal of the door. In other examples, one
or more other materials may be used to construct bracket 24 and/or base member 26,
provided the material(s) is sufficiently rigid and/or stiff to perform as described
herein.
[0016] In the example embodiment, as shown in Fig. 2, charging station 10 includes a gasket
46 disposed substantially about opening 18 and coupled to housing 12. Gasket 46 is
configured to be compressed between door 20 and housing 12 to substantially seal opening
18 when door 20 is disposed in the closed position. In this manner, gasket 46 cooperates
with door 20 and housing 12 to inhibit the ingress of, for example, weather, debris,
insects, and rodents into housing 12. While gasket 46 is coupled to housing 12 in
the example embodiment, it should be understood that gasket 46 may be coupled to door
20 in other charging station embodiments. In at least one embodiment, gasket 46 includes
single or multiple segments, disposed completely or partially about opening 18, with
at least one of the segments mounted on housing 12 and/or at least one of the segments
mounted on door 20. In such an embodiment, the gasket segments cooperate to substantially
seal opening 18.
[0017] Referring again to Fig. 1, charging station 10 includes a latching mechanism 48 coupled
between housing 12 and door 20. In the example embodiment, latching mechanism 48 is
configured to lock when door 20 is moved to the closed position, to prevent unauthorized
access to charging station 10. Latching mechanism 48 may be keyed and/or operable
by a specialized tool to substantially limit access to only authorized persons. As
shown in Figs. 1 and 4, latching mechanism 48 is coupled to a first end portion 50
of door 20, and bracket 24 is coupled to a bottom section 52 of door 20. In the example
embodiment, first end portion 50 is opposite bottom section 52. In other embodiments,
the relative orientations of hinge assembly 22 and latching mechanism 48 may be different,
potentially to provide efficient manufacture and/or latching of latching mechanism
48.
[0018] Fig. 10 illustrates an example method 100 for use in assembling charging station
10. While methods herein, including method 100, are described with reference to charging
station 10, it should be appreciated that the methods herein are not limited to charging
station 10 and may be used with other charging station embodiments. Similarly, charging
station 10 should not be understood to be limited to the methods described with reference
to Figs. 10 and 11.
[0019] Method 100 includes positioning 102 a door, such as door 20 shown in Fig. 2, proximate
to an opening, such as opening 18 of Fig. 2, and inserting 104 a projecting member,
such as projecting member 28 of Fig. 4, into an aperture of a base member, such as
base member 26 of Fig. 4. In the example embodiment, inserting 104 the projecting
member includes inserting the projecting member into the aperture until shoulders,
such as shoulders 32 and 34 of Fig. 4, contact the base member. Communication between
the projecting member and the base member prevent removal of the door in at least
one open position. Upon insertion of the projecting member, method 100 includes rotating
106 the door relative to the housing into the closed position (as shown in Figs. 1
and 4) to substantially cover the opening of the housing.
[0020] In the example embodiment, because the hinge assembly is operable by inserting 104
the projecting member into the aperture, no fasteners are required to couple the door
to the housing. As such, the door is removable without tools by rotating the door
and sliding the projecting member, specifically a tab, such as tab 36 shown in Fig.
8, out of the base member. In this manner, a technician is permitted to remove the
door and to access the interior of the housing, without the door at least partially
impeding the opening. Accordingly, given configuration, size, and/or shape constraints
often associated with charging station 10, a technician is provided with improved
access to vehicle charging components within the housing, as compared to known charging
stations with non-removable doors.
[0021] Furthermore, as illustrated in Figs. 4-6, projecting member 28 permits door 20 to
rotate relative to base member 26. At least partially due to tab 36 and the configuration
of aperture 38, projecting member 28 prevents removal of door 20 from housing 12 when
door 20 is positioned relative to housing 12 at one or more angles. Specifically,
as shown in Fig. 5, door 20 is positioned at the first open position relative to housing
12 (also shown in Fig. 2), such that a technician is able to slide projecting member
28 from aperture 38 by applying a force inline with door 20 and away from housing
12. Conversely, as shown in Fig. 6, when door 20 is positioned at the second open
position (also shown in Fig. 3), projecting member 28 and/or tab 36 contact base member
26 in response to the force described with reference to Fig. 4. In this embodiment,
the contact prevents removal of projecting member 28 from within aperture 38, thereby
preventing removal of door 20.
[0022] It should be appreciated that a threshold open position (not shown) exists between
the first open position and the second open position, at which projecting member 28
transitions from permitting or preventing removal of door 20. More specifically, in
the example embodiment, when door 20 is between the closed position (shown in Fig.
1) and the threshold open position, hinge assembly 22 permits removal of door 20.
Further, when door 20 is in the threshold open position or an open position beyond
the threshold open position, hinge assembly 22 prevents removal of door 20. In other
embodiments, threshold open positions can exist at various positions, in order to
define various angles between door 20 and housing 12, at which door 20 is permitted
or prevented from being removed. For example, if door 20 hinged from its top (rather
than its bottom as shown in Fig. 2), hinge assembly 22 may be configured prevent removal
between the closed position and the threshold open position, and permit removal at
or beyond the threshold open position. In still other embodiments, hinge assembly
22 is configured to provide multiple threshold open positions.
[0023] In the example embodiment, the first open position may be defined when door 20 is
positioned at a predetermined angle relative to side wall 54 of housing 12, as shown
in Fig. 2. The predetermined angle associated with the first position, for example,
may be between about 5 degrees and about 30 degrees, as shown in Fig. 5. It should
be appreciated that various predetermined angles between door 20 and side wall 54
of housing 12 may be defined at which door 20 is removable. For example, a range of
angles for the first open position may be defined by the effects of gravity on door
20. Hinge assembly 22, for example, is disposed at the lower portion of door 20 as
shown in Fig. 1. Accordingly, when unlatched, gravity biases door 20 into a fully
opened position, for example, the second open position illustrated in Fig. 6. If door
20 is retained in the second open position by tab 36 and base member 26, door 20 is
restrained from being removed. Because gravity biases door 20 out of the first open
position (as shown in Fig. 5) and into the second position, the potential for unintentional
removal of door 20 may be reduced.
[0024] It should be appreciated that hinge assembly 22 may be oriented and/or positioned
at various locations between door 20 and housing 12, to potentially inhibit unintentional
removal of door 20, assist in removal of door 20, and/or other reasons related to
the appearance, operation, and/or manufacture of other charging station embodiments.
[0025] Referring to Fig. 1, when door 20 is disposed in the closed position, bracket 24
and base member 26 are disposed within interior 14. Moreover, door 20 is disposed
within opening 18 and/or interior 14. In this manner, charging station 10 provides
improved resistance to unauthorized access, as compared to known charging stations
with one or more hinges external to the charging station. Furthermore, by providing
hinge assembly 22 within interior 14 when door 20 is disposed in the closed position,
door 20 is capable of providing access to interior 14, while accommodating a variety
of differently shaped doors and without substantially impacting the aesthetic appearance
of charging station 10.
[0026] Fig. 11 illustrates method 110 for use in operating charging station 10 for an electrically
powered vehicle. Method 110 includes providing 112 a door, such as door 20 of Fig.
1, positioned in a closed position substantially covering an opening of a housing,
such as housing 12 of Fig. 1, rotating 114 the door relative to the housing from the
closed position to a first open position, and extracting 116 a projecting member,
such as projecting member 28 of Fig. 2, from an aperture of a base member, such as
base member 26 of Fig. 4, to remove the door from the housing.
[0027] In at least one embodiment, rotating 114 the door relative to the housing to the
first open position includes rotating the door to define a predetermined angle between
the door and a side of the housing. The predetermined angle may be, for example, between
about 5 degrees and about 60 degrees. Additionally, or alternatively, method 110 may
include releasing latching mechanism, such as latching mechanism 48 of Fig. 1, configured
to retain the door in the closed position, prior to rotating the door relative to
the housing.
[0028] This written description uses examples to disclose the invention, including the best
mode, and also to enable any person skilled in the art to practice the invention,
including making and using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the claims, and may include
other examples that occur to those skilled in the art. Such other examples are intended
to be within the scope of the claims if they have structural elements that do not
differ from the literal language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages of the claims.
1. A charging station (10) for use in charging an electrically powered vehicle, said
charging station comprising:
a housing (12) defining an interior (14) and an opening (18) configured to permit
access to the interior;
a door (20) configured to substantially cover the opening, and
a hinge assembly (22) configured to removably couple said door to said housing and
to provide a pivotal movement of said door relative to said housing between at least
a closed position, a first open position, and a second open position, said hinge assembly
comprising a base member (26) coupled to one of said housing and said door and a bracket
(24) coupled to the other of said housing and said door, said base member defining
an aperture (38), said bracket including a projecting member (28) configured to be
operably disposed within the aperture, said projecting member and said base member
configured to permit removal of said door from the housing when said door is in the
first open position, said projecting member and said base member configured to prevent
removal of said door from the housing when said door is in the second open position.
2. The charging station (10) of Claim 1, wherein said base member (26) and said projecting
member (28) are disposed within the interior (14) when said door (20) is in the closed
position.
3. The charging station (10) of Claim 1 or Claim 2, wherein said projecting member (28)
includes at least one shoulder (32,34) configured to contact said base member (26)
to limit extension of said projecting member through the aperture (38).
4. The charging station (10) of Claim 3, wherein said at least one shoulder (32,34) comprises
two shoulders on oppositees of said bracket (24).
5. The charging station (10) of any preceding Claim, wherein said bracket (24) comprises
a mounting member (30) coupled to said door (20), that is substantially parallel with
and offset from said projecting member (28).
6. The charging station (10) of any preceding Claim, wherein said projecting member (28)
comprises a tab (36) having a first portion (56) and a second portion (58), said second
portion configured to retain said projecting member within the aperture (38) when
said door (20) is in the first open position.
7. The charging station (10) of Claim 6, wherein said second portion (58) of said tab
(36) is angled (41) at an obtuse angle with respect to said first portion (56) of
said tab.
8. The charging station (10) of any preceding Claim, further comprising multiple vehicle
charging components (16) at least partially enclosed within the interior (14).
9. The charging station (10) of any preceding Claim, further comprising a gasket (46)
coupled to at least one of said housing (12) and said door (20) and configured to
substantially seal the opening (18) when said door is disposed in the closed position.
10. The charging station (10) of any preceding Claim, wherein said door (20) has a trapezoidal
shape.
11. The charging station (10) of any preceding Claim, further comprising a latching mechanism
coupled to at least one of said housing and said door and configured to retain said
door in the closed position.
12. A charging station (10) for use in charging an electrically powered vehicle, said
charging station comprising:
a housing (12) defining an interior (14) and an opening (18) configured to permit
access to said interior;
a door (20) configured to substantially cover said opening; and
a hinge assembly (22) configured to removably couple to said door and said housing,
said hinge assembly configured to provide a pivotal movement of said door relative
to said housing between at least a closed position and an open position, said hinge
assembly configured to permit removal of said door from said housing when said door
is between the closed position and the open position, said hinge assembly configured
to prevent removal of said door from said housing when said door is in the open position.
13. The charging station of Claim 12, wherein said hinge assembly comprises a base member
(26) having an aperture extending therethrough and a bracket including a projecting
member (28) disposed within the aperture to provide relative movement between said
door and said housing.
14. The charging station of Claim 13, wherein said projecting member (28) comprises a
tab having a first portion and a second portion, said second portion configured to
retain said projecting member within the aperture when said door is between the closed
position and the open position, and preferably said second portion of said tab is
angled with respect to said first portion of said tab.
15. A method for use in operating charging station for an electrically powered vehicle,
the charging station including a housing defining an opening configured to permit
access to an interior of the housing and a base member positioned within the interior
and adjacent to the opening, said method comprising:
providing a door positioned in a closed position substantially covering the opening
of a housing, a projecting member of a bracket coupled to the door and positioned
within an aperture defined by the receptacle;
rotating the door relative to the housing from the closed position to a first open
position; and
extracting a projecting member coupled to one of the door and the housing from an
aperture of a base member to remove the door from the housing.